US10427358B2 - Method for manufacturing a rivet connection of a fiber composite component - Google Patents

Method for manufacturing a rivet connection of a fiber composite component Download PDF

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Publication number
US10427358B2
US10427358B2 US15/604,277 US201715604277A US10427358B2 US 10427358 B2 US10427358 B2 US 10427358B2 US 201715604277 A US201715604277 A US 201715604277A US 10427358 B2 US10427358 B2 US 10427358B2
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Prior art keywords
component
drilling
laser
fiber composite
hole
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US15/604,277
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US20170355151A1 (en
Inventor
Paul Jörn
Peter Linde
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Airbus Operations GmbH
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Airbus Operations GmbH
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Assigned to AIRBUS OPERATIONS GMBH reassignment AIRBUS OPERATIONS GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JÖRN, Paul, LINDE, PETER
Publication of US20170355151A1 publication Critical patent/US20170355151A1/en
Priority to US16/574,795 priority Critical patent/US20200023590A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B23K26/0624—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses using ultrashort pulses, i.e. pulses of 1ns or less
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/16—Removal of by-products, e.g. particles or vapours produced during treatment of a workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/40—Removing material taking account of the properties of the material involved
    • B23K26/402—Removing material taking account of the properties of the material involved involving non-metallic material, e.g. isolators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/601—Riveting or staking using extra riveting elements, i.e. the rivets being non-integral with the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024—Thermal pre-treatments
    • B29C66/0246—Cutting or perforating, e.g. burning away by using a laser or using hot air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/10—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer reinforced with filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B19/00—Bolts without screw-thread; Pins, including deformable elements; Rivets
    • F16B19/04—Rivets; Spigots or the like fastened by riveting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0838—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using laser
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
    • B29C66/02241—Cutting, e.g. by using waterjets, or sawing
    • B29C66/02242—Perforating or boring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles

Definitions

  • the present disclosure relates to a method for manufacturing a rivet connection of a fiber composite component, to a use of a laser-drilling process to manufacture a rivet connection of a fiber composite component, to a structural arrangement comprising a rivet connection of this type, to a method for manufacturing a vehicle skin and to a vehicle skin.
  • Modern airplane fuselages are often constructed using fiber composite materials, generally carbon-fiber-reinforced plastics materials.
  • An airplane fuselage conventionally comprises a plurality of skin portions which are interconnected to assemble the airplane fuselage. To fix the skin portions together, riveting methods are conventionally used, this often being required for certification or authorisation.
  • An idea behind the present disclosure is to use a laser-drilling process to manufacture a rivet connection of a fiber composite component.
  • the light energy of the laser beam focussed on the material is absorbed by the fiber composite material, in other words converted into heat, in such a way that the material evaporates without dust occurring.
  • the material volume in the drill hole expands, in such a way that high vapor pressure occurs locally. This vapor pressure subsequently also drives any molten material out of the drill hole.
  • the simplest type of laser-drilling is single-pulse drilling, in which the material is drilled through using a single, sufficiently temporally long laser pulse.
  • the material is removed by the impingement of a plurality of pulses in succession on the same point.
  • the laser beam is passed around the centre of the drill hole, and thus successively widens the diameter.
  • a smaller through-hole can be produced beforehand by percussion drilling.
  • each of these options is a very rapid process by comparison with conventional drilling, and takes only a fraction of the time, in particular just fractions of a second.
  • the energy consumption per hole drilled can also be reduced in this way.
  • laser-drilling is can also be automated or at least partially automated better, since the through-holes can be positioned and reproduced with a very high accuracy of repetition.
  • the step of positioning a drilling template can be omitted.
  • a drilling template may further be provided as a positioning aid.
  • the laser optics can be oriented onto the hole provided in the drilling template and thus positioned for the laser-drilling.
  • the drilling template may be arranged stationary, in such a way that the components to be connected can be oriented on the drilling template in the desired position. In this case, a plurality of adjacent holes can be drilled in an automated manner after the orientation.
  • the second component with pre-drilled holes, in such a way that the shared through-hole can only be produced through the fiber composite material of the first component by laser-drilling.
  • holes pre-drilled in this manner in the second component may comprise depressions for receiving a rivet head in a flush manner.
  • both the first component and the second component are drilled through during laser-drilling.
  • a shared through-hole is laser-drilled through the fiber composite material of the first component and through the second component.
  • Laser beam optics are generally guided using a robot, in particular an industrial robot. In this way, the laser beam can be oriented.
  • movable laser beam optics known as scanners which make it possible to orientate and guide the laser beam by beam deflection.
  • this also makes laser-machining possible “on the fly”, in other words without halting the robot carrying the optics, and this can further reduce the machining time.
  • the (human) working time required for manufacture can be massively reduced, as well as the manufacturing time. This effect may have enormous potential for example in airplane manufacture, in which millions of rivets are placed every year.
  • the high reproducibility according to the disclosure herein is because unlike a drill the laser beam can operate without wear. Thus, in laser-drilling, even for large numbers of holes, no deviation in the hole geometry and no worsening of the hole wall, in particular no increase in roughness, are observed.
  • the method according to the disclosure herein may also be used flexibly for different types of composite materials.
  • it may equally be used both for components containing composite materials having a thermoplastic matrix and for components containing composite materials having a thermoset matrix.
  • the method according to the disclosure herein can therefore be used for manufacturing a wide range of structural arrangements comprising rivet connections, for example both for a wide range of skin portions of an airplane, such as on the fuselage, the wings or the like, and for example for fiber composite material skin portions on land vehicles or boats. Further, use of the method according to the disclosure herein to connect a skin portion to other types of structural parts, for example to connecting or stabilizing elements, known as clips or cleats, or directly to stringers and/or formers is also conceivable.
  • the second component as a joining partner of the first component which contains a fiber composite material, may comprise an identical or different material.
  • the shared through-hole through the first and second components may be manufactured in a shared manufacturing step by laser-drilling. In this way, the complexity of positioning is kept to a minimum.
  • the shared through-hole in two separate steps or in a two-step process by laser-drilling.
  • the components may therefore be positioned in an overlap joint either before or only after the shared through-hole is laser-drilled, naturally coincidently with the shared through-hole.
  • the laser-drilling is carried out using a high-energy laser beam.
  • the intensity of the laser beam is in a range which makes it possible to evaporate both the matrix material and the fibers of the fiber composite material.
  • this is a laser beam having a laser power in the kilowatt range.
  • solid-state lasers for example a disc laser (for example Nd:YAG: neodymium-doped yttrium aluminium garnet) or fiber laser (for example an ytterbium fiber laser), are conceivable.
  • a high-power gas laser in particular a CO 2 laser, would also be conceivable.
  • this may be a high-brilliance laser beam.
  • the brilliance is generally the characteristic value for the beam quality. At high brilliance, high beam intensities are possible, in other words beams having particularly high energy per area, and this advantageously leads to a high proportion of sublimated material. Further, this is possible in a comparatively large region of the beam path around the focal position of the laser beam. For example, a high brilliance can be achieved using an ytterbium fiber laser.
  • the second component likewise contains a fiber composite material. This is also drilled through during the laser-drilling.
  • the two fiber composite components are provided with a shared through-hole. In particular, this is carried out in a shared step in the overlap joint. In this way, in particular a fiber composite construction of a structural arrangement comprising a rivet connection can be manufactured rapidly and without dust.
  • the fiber composite material comprises carbon fibers, some of which are drilled through by the laser-drilling.
  • this is implemented without the occurrence of carbon dust or without carbon dust.
  • the fiber composite material is carbon-fiber-reinforced plastics material. Both thermoplastic and thermosetting plastics materials are conceivable as matrix materials.
  • a laser beam for laser-drilling is widened or defocussed in a manner adapted to a desired hole diameter.
  • the widening or defocussing is also adapted during laser-drilling as a function of the hole depth reached.
  • different diameters and hole shapes of the through-hole can be implemented, in particular diameters of a few millimeters typically provided for rivets.
  • the intensity of the laser beam remains in a range which makes it possible to evaporate both the matrix material and the fibers of the fiber composite material.
  • the laser beam is initially more heavily widened or defocussed, and subsequently less and less so down to the desired hole diameter, to form a conical entry to the through-hole which is formed for countersinking a rivet head.
  • this is adapted to the geometry of the rivet in a predetermined manner as a function of the achieved hole depth.
  • At least the first component is provided in planar form.
  • a multiplicity of shared through-holes of the first component and second component are formed by laser-drilling in a line extending along an edge of the first component.
  • a rivet is inserted into each of the through-holes and fixed to the first and the second component.
  • the holes are placed at uniform distances, in such a way that a uniformly continuous joint line is manufactured.
  • a plurality of parallel joint lines are provided along the edge of the first component.
  • redundancy in the rivet connection is provided, in such a way that a higher support loading capacity and a higher strength are achieved.
  • the rigidity of the structural arrangement created by the rivet connections is also increased.
  • a structural arrangement for example of an aircraft or spacecraft is typically a rivet connection comprising three joint lines, as is conventional for aviation.
  • a through-hole of the rivet connection comprises a hole wall which comprises a surface manufactured without cutting.
  • the hole wall manufactured by laser-drilling is in particular free of grooves normally brought about by cutting tools or conventional drills.
  • the constitution of the hole wall is also different from in etched holes, since in composite materials etching always brings about a different surface structure on the different materials.
  • the hole wall manufactured by laser-drilling may instead be covered with material directly solidified from a molten liquid state. This is material melted by the laser beam which has been left behind on the cavity wall when the melt was driven out or has been melted on during the evaporation.
  • the surface may also be manufactured by direct evaporation. This surface structure of the hole wall is therefore clearly distinguishable by conventional analysis methods, for example under a microscope, from a conventionally drilled hole wall, which usually has machining traces and/or a certain roughness and/or drilling dust.
  • the laser-drilling process for manufacturing a rivet connection of a vehicle skin by a method according to the disclosure herein is used.
  • the vehicle skin is the skin, for example the fuselage, of an aircraft or spacecraft.
  • the method according to the disclosure herein is also usable in other skin portions of an aircraft or spacecraft, for example the skin of a wing.
  • the method according to the disclosure herein is also usable in the manufacture of a vehicle skin for other types of vehicles, for example motor vehicles or boats.
  • FIG. 1 is a perspective view of an example of manufacturing through-holes for rivet connections
  • FIG. 2A-2C are cross-sectional drawings of the typical steps for manufacturing a rivet connection for connecting two skin portions
  • FIG. 3A shows an arrangement for laser-drilling a fiber composite component
  • FIG. 3B is a cross-sectional view of a fiber composite material component drilled through by laser-drilling
  • FIG. 4A shows an arrangement for drilling through two fiber composite material components in an overlap joint
  • FIG. 4B is a cross-sectional view of a structural arrangement comprising a rivet connection of two fiber composite material components
  • FIG. 5 is a perspective drawing of a fuselage portion of an aircraft or spacecraft.
  • FIG. 6 is a perspective drawing of two fiber composite material components connected in a butt joint by a connecting portion.
  • FIG. 1 is a perspective view of an example of manufacturing through-holes 103 for rivet connections.
  • the components to be connected are two skin portions 101 and 102 of a fiber composite material airplane fuselage.
  • a drilling template 106 is manually positioned and fixed, for example by an adhesive strip 107 as shown.
  • a through-hole 103 is drilled in the skin portions 101 , 102 using a hand-operated power drill 105 .
  • FIG. 2A-2C are cross-sectional drawings of the typical steps for manufacturing a rivet connection for connecting two skin portions 101 , 102 .
  • through-holes 103 are drilled in an overlap region of the fiber composite material skin portions 101 , 102 in the manner described in FIG. 1 , by mechanical cutting using a hand-operated power drill at a position specified using a drilling template 106 .
  • the through-holes 103 are cleaned of drilling dust and residues. This takes place for example by pressurised air from both sides, as is indicated schematically using flow lines and directional arrows.
  • This cleaning step is important when fiber composite materials are machined using a conventional drill, since very fine carbon dust occurs when the material is cut and easily accumulates in the hole 103 .
  • rivets 104 are introduced into the through-holes 103 by a riveting tool (not shown) and fixed to the two skin portions 101 , 102 by deforming the rivet.
  • FIG. 3A shows an arrangement for laser drilling a fiber composite component.
  • a first component 1 made of carbon-fiber-reinforced plastics material is provided as the fiber composite component.
  • the arrangement comprises laser optics 8 , which are carried and positioned by a robot 7 .
  • the robot 7 may for example be a conventional industrial robot having a suitable mounting.
  • the laser optics 8 are supplied with laser radiation from a laser source 9 via an optical fiber 15 .
  • the laser source 9 is a high-energy solid-state laser, in particular a disc laser or fiber laser, having a laser power in the kilowatt range.
  • a laser beam 5 generated thereby has a high brilliance.
  • the brilliance B is defined as the quotient of the laser power P L divided by the product of the beam quality factor M 2 and the wavelength ⁇ of the laser beam.
  • the beam quality factor M 2 denotes the degree of divergence of the beam path. It is known in principle to a person skilled in the art how to derive the beam quality factor for transverse electromagnetic modes (TEM mn ), and so a theoretical explanation is omitted herein.
  • the brilliance which can be calculated in this manner is a measure of the quality of the laser beam.
  • the beam parameter product (BPP) based on the beam quality factor M 2 in terms of calculation, is often given in connection with the laser power P L so as to express the beam quality.
  • the laser optics are positioned above a first fiber composite material component 1 to be drilled through by a robot 7 in such a way that the focal position of the laser beam 5 is at the level of the first component 1 .
  • the laser beam can be focussed to a minimum diameter corresponding to the fiber diameter of the optical fiber 15 .
  • a multiplicity of laser pulses are emitted onto the first component, for example by percussion drilling, in such a way that the material of the first component 1 evaporates, the laser beam 5 digs further into the first component 1 , and material vapor 10 escapes from the resulting hole. This is repeated until a through-hole is manufactured.
  • the laser beam 5 evaporates both the matrix material and the fiber material of the fiber composite material equally.
  • the laser beam evaporates both the plastics material matrix and the carbon fibers in the region of the through-hole.
  • thermophysical properties of the fibers and the matrix material particular constraints should be adhered to when laser-drilling fiber composite materials.
  • Thresholds of this type may for example be the glass transition temperature and the evaporation temperature, and in the case of thermoplastic systems the melting point of the matrix.
  • the intensity of the laser beam is selected to be appropriately high so as to be able to evaporate both the matrix material and the fibers of the fiber composite material.
  • a through-hole manufactured by percussive drilling can be widened by trepanning, in other words moving the component or the laser optics in a circle around the centre of the through-hole.
  • a spiral drilling process may be used or carried out to drill through the first component 1 .
  • the laser beam for example using movable mirror optics, known as a scanner
  • the laser beam optics by moving the robot accordingly
  • the first component by moving a mounting accordingly
  • superposed movements are also conceivable, in particular in the case of a scanner provided as laser optics and mounted on the robot.
  • An alternative to laser-drilling involves directing a high-energy laser beam having sufficiently high laser power, for example a CO 2 laser, a fiber laser or a disc laser, for example having a power >3 kW, in particular >6 kW, onto the first component 1 in a configuration in which a beam diameter directly corresponds to the desired diameter of the through-hole.
  • a high-energy laser beam having sufficiently high laser power for example a CO 2 laser, a fiber laser or a disc laser, for example having a power >3 kW, in particular >6 kW
  • This is the case in FIG. 3A , and can be achieved by way of appropriately configured laser optics 8 having an appropriate imaging ratio, by optically defocussing the laser beam 5 , by adjusting a relevant distance from the focal position and/or by way of an appropriately thick diameter of an optical fiber from the laser source to the laser optics. Because of the high power, the intensity of the laser beam 5 is still high enough to evaporate the material both of the matrix and of the fibers of the fiber composite material.
  • drilling process are merely examples of a possible implementation. Further drilling strategies or drilling processes are also possible.
  • a continuous laser may be used as a laser source.
  • a pulsed laser would also be conceivable.
  • FIG. 3B is a cross-sectional view of a fiber composite material component drilled through by laser-drilling.
  • This first component 1 accordingly comprises a through-hole 3 .
  • the hole wall 11 manufactured by laser-drilling, of the through-hole 3 is a completely smooth and clean surface without residues of the drilling dust. It is in particular a surface which is covered with material directly solidified from the molten liquid state or which is manufactured by direct evaporation.
  • the material melted on by the laser beam 5 has for example been left behind on the hole wall 11 when the melt was driven out or been melted on during the laser-drilling.
  • FIG. 4A shows an arrangement for drilling through two fiber composite material components 1 , 2 in an overlap joint.
  • the two components 1 , 2 arranged in an overlap joint consist of or comprise for example carbon-fiber reinforced plastics material and are occupied by a drilling template 6 , for positioning or orientating the laser optics 8 , on a face provided for the entry of the laser beam 5 .
  • the laser optics 8 are mounted on a robot 7 .
  • the associated laser source 9 and the optical fiber 15 which supply the laser optics, are not shown here for improved clarity.
  • the embodiment shown is in particular a semi-automatic system.
  • the laser optics 8 are oriented onto recesses provided in the drilling template 6 , in a robot-assisted manner but under the control of a user.
  • the laser source 9 comprises a search laser which emits a visible light beam through the fiber in such a way that a light point is projected onto the targeted point by the laser optics.
  • the drilling template 6 may also be fixed in position and be formed as a positioning means or stop for the first and second components 1 , 2 .
  • the approach towards the positions for drilling may be programmed or saved (for example by learning or teaching) into a control system of the robot 7 .
  • a laser machining pattern or a machining sequence may be programmed into a control system of the laser source 9 and/or of the laser optics 8 .
  • an automatic sequence of the drilling process can be initiated.
  • an automatic sequence of the drilling process could also be initiated without a template.
  • the through-holes 3 are formed by laser-drilling in the manner described in relation to the previous FIGS. 3A and B.
  • the laser beam is initially more heavily defocussed, and subsequently less and less so down to the desired hole diameter.
  • the intensity of the laser beam always remains high enough to evaporate both the matrix material and the fibers of the fiber composite material.
  • arrangements of this type advantageously operate without any variation in the quality of the laser-drilled through-holes 3 .
  • a drill loses sharpness and thus precision with continued use. This can be discerned in microscope images of the drilled holes by way of increased occurrence of drilling dust and unclean or rough surfaces.
  • FIG. 4B is a cross-sectional view of a structural arrangement 16 comprising a rivet connection 17 of two fiber composite material components 1 , 2 .
  • the two components 1 , 2 arranged in an overlap joint and provided with through-holes 3 by laser-drilling are connected by rivets 4 , which are introduced into the through-holes 3 and subsequently fixed to the first component 1 and to the second component 2 .
  • the fixing takes place in the manner conventional to a person skilled in the art, in particular by way of a positive connection provided on the rivet 4 by way of a rivet head at the entry face and a positive and non-positive connection provided by shaping at the exit face.
  • FIG. 5 is a perspective view of a vehicle skin 20 .
  • this is a vehicle skin 20 in the form of a fuselage portion of an aircraft or spacecraft.
  • the fuselage portion comprises a first skin portion 18 as the first component 1 and a second skin portion 19 as the second component 2 .
  • the two skin portions 18 , 19 are arranged in an overlap joint with one another in the region of a rivet connection 17 .
  • a plurality of joint lines 13 are provided parallel to an edge 14 of the first skin portion 18 by through-holes, each having an inserted and fixed rivet 4 .
  • the fuselage portion shown consists of or comprises by way of example four skin portions, which are each curved and which are arranged to form a tubular fuselage shape and interconnected in the same manner as the first skin portion 18 and the second skin portion 19 .
  • FIG. 6 is a perspective view of two fiber composite material components 1 , 12 connected in a butt joint by a connecting portion 2 ′.
  • the first component 1 and a further component 12 are arranged with respect to one another and covered with a connecting portion 2 ′ formed as a doubler in the region of the butt joint.
  • the connecting portion 2 ′ is arranged overlapping with each of the components 1 , 12 and in each case connected by at least one joint line 13 of through holes 3 , for example a plurality as shown here, in particular three, each having an inserted and fixed rivet 4 .
  • the connecting portion 2 ′ formed as a doubler forms the second component arranged in an overlap joint with the first component 1 and connected by rivet connection.
  • the joint lines 13 accordingly extend along an edge 14 of the first component 1 .
  • rivets may be used, for example including hollow rivets, blind rivets, spread rivets or the like instead of solid rivets.
  • one of the components with pre-drilled holes, in such a way that the shared through-hole can only be produced through the fiber composite material of the other component by laser-drilling. Subsequently, the components can be riveted.
  • holes of the pre-drilled component which are pre-drilled in this manner may be provided with countersinks for receiving a rivet head in a flush manner.
  • first and second components 1 , 2 may be any type of structural component of a structural arrangement.
  • skin portions of other types of vehicle skins containing fiber composite components may be provided with a rivet connection 17 in the manner according to the disclosure herein, for example body parts of a motor vehicle or fuselage parts of a boat or ship.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Thermal Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Electromagnetism (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Toxicology (AREA)
  • Insertion Pins And Rivets (AREA)
  • Connection Of Plates (AREA)
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